Method of fabricating 3D vacuum insulated refrigerator structure having core material

ABSTRACT

A method of fabricating a vacuum insulated refrigerator structure includes positioning a first barrier film in a female mold cavity. Porous filler material is positioned on the barrier film, and a second barrier film is positioned over the porous filler material. A male mold is brought into contact with the second barrier film to deform and compress the porous filler material into a 3D shape. A vacuum is formed between the first and second barrier films, and the first and second peripheral edge portions are sealed together to form a vacuum insulated core. The vacuum insulated core may be positioned between a liner and a wrapper to form an insulated refrigerator cabinet, door, or other vacuum insulated component.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a Continuation of U.S. patent application Ser. No. 14/984,347 filed on Dec. 30, 2015, entitled “METHOD OF FABRICATING 3D VACUUM INSULATED REFRIGERATOR STRUCTURE HAVING CORE MATERIAL,” which is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

Various types of vacuum insulated refrigerator cabinets, doors, and other such structures have been developed. However, known methods of forming vacuum insulated structures may suffer from various drawbacks and limitations.

SUMMARY OF THE INVENTION

A method of fabricating a vacuum insulated refrigerator structure includes positioning a first barrier film in a female mold cavity. Porous filler material is positioned on the first barrier film, and a second barrier film is positioned over the porous filler material. The first and second barrier films have first and second peripheral edge portions, respectively. The porous filler material is disposed between the first and second barrier films. A male mold is brought into contact with the second barrier film to thereby cause the porous filler material to deform into a 3D shape including a central portion and at least one sidewall portion that extends transversely from the central portion. A vacuum is formed between the first and second barrier films, and the first and second peripheral edge portions are sealed together to form a vacuum insulated core having porous filler material disposed in a vacuum. The vacuum insulated core may be positioned between a liner and a wrapper to form an insulated refrigerator cabinet, door, or other insulated refrigerator component.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a refrigerator;

FIG. 2 is a partially schematic view of a female mold part and first barrier film;

FIG. 3 is a partially schematic view showing porous insulation powder disposed over at least a portion of the first barrier film in the female mold part;

FIG. 4 is a partially schematic view of a male mold part having a second barrier film positioned on the male mold part;

FIG. 5 is a partially schematic view showing a core position between male and female mold parts;

FIG. 6 is a partially schematic view showing the mold inside a vacuum chamber;

FIG. 7 is a partially schematic view showing the mold inside a vacuum chamber as the peripheral edge portions of the first and second barrier films are sealed together;

FIG. 8 is a partially schematic cross sectional view of a 3D vacuum insulated core disposed between a liner and wrapper; and

FIG. 9 is a cross sectional view of a vacuum insulated refrigerator structure taken along the line IX-IX; FIG. 1 .

DETAILED DESCRIPTION

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 2 . However, it is to be understood that the disclosure may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

With reference to FIG. 1 , a refrigerator 1 may include a vacuum insulated cabinet 2 forming a fresh food compartment 4 and a freezer compartment 6. Doors 8 and 10 are movably mounted to the cabinet 2, and selectively close off an access opening 12 that provides access to the fresh food compartment 4. A door or drawer 14 selectively closes off an access opening 16 that provides access to freezer compartment 6. A cooling system (not shown) including a compressor, condenser, evaporator, and other related components may be positioned in a machine compartment 18 located at a lower rear portion of cabinet 2. Door 8 may include an ice/water dispenser 20.

The cabinet 2 may comprise a vacuum insulated structure having an outer wrapper 22, an inner liner 24 that fits within the outer wrapper 22, and a vacuum insulated core structure 26 that is disposed between the wrapper 22 and liner 24. One or more of the doors 8, 10, and 14 may also comprise vacuum insulated structures having an outer wrapper or panel, inner liner, and vacuum insulated core disposed between the outer panel and the inner liner.

With reference to FIGS. 2-5 , the cabinet 2 and/or doors 8, 10, and 14 may be fabricated utilizing a female mold 30 and a male mold 40. The female mold 30 may include a generally planar interior surface 32 and one or more inwardly facing side walls or surfaces 34 that together form a mold cavity 36. In the illustrated example, the female mold 30 includes four generally planar side surfaces 34 that are orthogonal relative to one another such that female mold 30 is generally bathtub-shaped.

A vacuum insulated core component may be fabricated by placing a first barrier film 38 in the mold cavity 36 with the first barrier film 38 positioned closely against surfaces 32 and 34. The first barrier film 38 includes peripheral edge portions 39 that are positioned directly against edge surfaces 33 of female mold 30. With further reference to FIG. 3 , porous filler material 50 is then positioned in the female mold cavity 36 over at least a portion of first barrier film 38. Porous filler material 50 may comprise silica powder, glass fibers, or other suitable material that is capable of being deformed as required for a particular application.

With reference to FIG. 4 , a male mold part 40 includes a generally planar central portion 42, outwardly-facing side surfaces 44, and edge surface portions 43. Male mold part 40 may include four outwardly facing surfaces 44 that are orthogonal relative to one another. A second barrier film 48 is positioned over or on the male mold 40, and the female and male mold components 30 and 40 are then brought together as shown in FIG. 5 to compress the silica powder 50 between barrier films 38 and 48. Alternatively, second barrier film 48 may be positioned over female mold 30 as shown by dashed lines 48A rather than positioning second barrier film 48 on male mold 40. The peripheral edge portions 39 and 49 of barrier films 38 and 48 overlap one another, and may be pressed together by surfaces 33 and 43 of female and male mold parts 30 and 40, respectively.

With further reference to FIG. 6 , the female and male mold parts 30 and 40 are then positioned within a vacuum chamber 52, and air is evacuated from the vacuum chamber 52 through an opening or passageway 54 utilizing a vacuum pump (not shown) or other suitable mechanism to thereby form a vacuum in the space 56 inside vacuum chamber 52. With further reference to FIG. 7 , the peripheral edge portions 39 and 49 of barrier films 38 and 48, respectively are then sealed along a seal line 58 utilizing heat sealing, adhesives, or other suitable known processes. The seal line 58 may include 4 substantially straight edge portions if the refrigerator component (e.g. cabinet 2, or doors 8, 10, or 14) have a rectangular perimeter. Barrier films 38 and 48 may comprise multilayer polymer and/or metal foil that is impervious to oxygen, nitrogen, carbon dioxide water vapor, and other gasses as may be required to maintain a vacuum.

With further reference to FIGS. 8 and 9 , vacuum insulated core 26 is then removed from the vacuum chamber 52, and the core 26 is positioned between a wrapper 22 and a liner 24 to form a 3D vacuum insulated refrigerator component 60. The wrapper 22 and liner 24 may be interconnected utilizing known structures and processes. A small gap or space 66 (FIG. 9 ) may be formed between vacuum insulated core 26 and outer wrapper 22. Similarly, a small gap or space 68 may be formed between liner 24 and vacuum insulated core 26. The gaps 66 and/or 68 may be filled with adhesive and/or polyurethane foam (not shown) to interconnect the vacuum insulated core 26 to the wrapper 22 and liner 24, and to fill the gaps 66 and 68 to reduce or prevent flexing of wrapper 22 and liner 24. If the refrigerator component 60 comprises a cabinet 2, the forward edge 64 of the cabinet 2 may include an edge strip 62 that is sealingly connected to the wrapper 22 and liner 24.

It will be understood that the 3D vacuum core may have various shapes and sizes as required for a particular application. For example, the 3D vacuum core may be configured to be utilized in a refrigerator cabinet as described above, or it may be configured to be utilized in a refrigerator door or other component.

It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise. 

What is claimed is:
 1. A method of fabricating a vacuum insulated refrigerator structure, the method comprising: providing a female mold having a female mold cavity that is defined by a central surface portion and a plurality of inwardly facing side wall surface portions that are transverse to the central surface portion, the female mold further including edge surfaces extending transversely outward from the inwardly facing side wall surface portions and away from the female mold cavity; providing a male mold having a central surface portion and a plurality of outwardly facing side wall surface portions that are transverse to the central surface portion of the male mold, the male mold further including edge surfaces extending transversely outward from the outwardly facing side wall surface portions; positioning the male and female molds in a vacuum chamber; positioning an impermeable first barrier film having a first peripheral edge portion in the female mold cavity adjacent to the central surface portion and adjacent to the inwardly facing side wall surface portions; positioning the first peripheral edge portion of the impermeable first barrier film over the edge surfaces of the female mold; positioning porous powder filler material on the impermeable first barrier film; followed by positioning an impermeable second barrier film having a second peripheral edge portion over the porous powder filler material whereby the porous powder filler material is disposed between the impermeable first and second barrier films; positioning the second peripheral edge portion of the impermeable second barrier film over the first peripheral edge portion of the impermeable first barrier film; bringing the female and male molds together; causing the male mold to press against the impermeable second barrier film to thereby deform the impermeable second barrier film from a first shape into a second shape; causing the central surface portion of the male mold and at least a portion of the plurality of outwardly facing side wall surface portions of the male mold to enter the female mold cavity thereby causing the second barrier film and the porous powder filler material to deform into a shape including a central portion having a substantially uniform thickness, the shape including at least one sidewall portion extending transversely from the central portion; causing the porous powder filler material to contact the impermeable first and second barrier films; followed by pressing the first and second peripheral edge portions together between the edge surfaces of the male and female molds by bringing the male and female molds together to define a closed configuration; followed by evacuating air between the impermeable first and second barrier films by forming a vacuum in the vacuum chamber; followed by sealing the first and second peripheral edge portions together along a seal line while the male and female molds are in the closed configuration in the vacuum chamber to form a vacuum insulated core; followed by removing the vacuum insulated core from the vacuum chamber; followed by positioning the vacuum insulated core between a wrapper and a liner; and followed by connecting the wrapper to the liner to form the vacuum insulated refrigerator structure.
 2. The method of claim 1, wherein: outer edges of the impermeable first and second barrier films are disposed outside of the male and female molds when the male and female molds are in the closed configuration.
 3. The method of claim 1, wherein: the impermeable second barrier film is planar prior to causing the male mold to press against the impermeable second barrier film.
 4. The method of claim 1, including: positioning the impermeable second barrier film on the male mold before bringing the male and female molds together.
 5. The method of claim 1, wherein: the central surface portion of the female mold cavity is substantially planar and free of protrusions.
 6. The method of claim 1, wherein: the central surface portion of the male mold cavity is substantially planar and free of protrusions.
 7. The method of claim 1, wherein: the inwardly facing side wall surface portions of the female mold are substantially orthogonal to the central surface portion.
 8. The method of claim 1, wherein: the central surface portion of the female mold and the central surface portion of the male mold are rectangular; the impermeable first and second barrier films comprise multilayer films; and the porous powder filler material comprises silica powder.
 9. The method of claim 1, wherein: the vacuum insulated refrigerator structure comprises a door.
 10. A method of fabricating a vacuum insulated refrigerator structure, the method comprising: providing a mold tool having a female mold and a male mold, wherein the female mold has a female mold cavity and a central surface portion, and wherein the male mold has a central surface portion; positioning a central portion of a first barrier film in the female mold cavity over the central surface portion; positioning porous powder filler material on the central portion of the first barrier film; positioning a central portion of a second barrier film over the female mold cavity; followed by bringing the female and male molds together; causing the male mold to deform the second barrier film from a first shape into a second shape, the second shape including a generally planar central portion and at least one sidewall portion extending transversely from the generally planar central portion; wherein bringing the female and male molds together further includes causing the female and male molds to compress the porous powder filler material; followed by forming at least a partial vacuum between the first and second barrier films; followed by sealing the first and second peripheral edge portions together to form a vacuum insulated core having porous powder filler material disposed in a vacuum formed between the first and second barrier films; followed by moving the female and male molds apart; followed by removing the vacuum insulated core from the mold tool; followed by positioning the vacuum insulated core between a wrapper and a liner; and connecting the wrapper to the liner to form the vacuum insulated refrigerator structure.
 11. The method of claim 10, wherein: the central surface portion of the female mold cavity is free of protrusions.
 12. The method of claim 10, wherein: the central surface portion of the male mold is free of protrusions.
 13. The method of claim 10, wherein: the central surface portion of the female mold is substantially planar; the female mold includes four inwardly facing side wall surface portions that are transverse to the central surface portion; the central surface portion of the male mold is substantially planar, the male mold including four outwardly facing side wall surface portions that are transverse to the central surface portion of the male mold.
 14. The method of claim 10, wherein: bringing the female and male molds together includes causing the central surface portion of the male mold to be disposed in the female mold cavity.
 15. The method of claim 10, wherein: the first and second barrier films comprise multilayer films.
 16. The method of claim 10, including: causing the first and second peripheral edge portions to overlap prior to sealing the first and second peripheral edge portions together.
 17. A method of fabricating a vacuum insulated refrigerator structure, the method comprising: positioning a first barrier film having a first peripheral edge portion in a female mold cavity; positioning porous filler material on the barrier film; positioning a second barrier film having a second peripheral edge portion over the porous filler material whereby the porous filler material is disposed between the first and second barrier films; utilizing a male mold that is in contact with the second barrier film to press the second barrier film and cause the porous filler material to deform into a shape including a central portion and at least one sidewall portion extending transversely from the central portion; evacuating air from between the first and second barrier films; and followed by sealing the first and second peripheral edge portions together to form a vacuum insulated core having porous filler material disposed in a vacuum.
 18. The method of claim 17, wherein: the female mold includes a generally planar central surface portion and at least one inwardly facing side wall surface portion that is generally orthogonal to the central surface portion.
 19. The method of claim 17, wherein: the male mold includes a generally planar central surface portion and at least one outwardly facing side wall surface portion that is generally orthogonal to the central surface portion of the male mold.
 20. The method of claim 19, wherein: the central surface portion of the female mold and the central surface portion of the male mold are substantially free of protrusions. 